Relay structure



No 21, 1945. H. E. BQCKLEN, JR, Em 2,389,

RELAY STRUCTURE Filed March 21, 1941 IN VENTORS ud l n U720 6.5903292.

Patented Nov. 27,

UNITED STATES PATENT? orrics RELAY STRUCTURE Herbert E. Bueklen, In, Elkhart, Ind and line C. Hedln, Des Moines, Iowa; said Bedln alaignor to said Bueklen, Jr.

Application March 21, 1941, Serial No. 384,542

2 Claims. (CL 200-87) This invention relates to metal envelope relay structures, and more particularly is directed to the hermetic sealing of an electromagnetic relay in such fashion that both the relay and the actuating coil are enclosed within a sealed metal envelope and subjected-to a hydrogen or inert gas atmosphere under pressure. The envelope may or maynot be a magnetic material.

One of the primary objects of the present invention is to place an electro-magnetic relay within a metal envelope in such manner that both the coil and the contacts are effectively insulated from atmosphere. The envelope is preferably evacuated and then filled with either hydrogen or an inert gas under pressure, whereby a non-oxidizing atmosphere is maintained at the contacts, preventing their deterioration or pitting and maintaining the contact surfaces, both of the armature and of the relay contacts, clean and bright.

It has been found heretofore that relays, when of time, may become coated with dust or moisture films producing rusting or rendering the contacts such that increased resistance through the relay is produced.

The present invention therefore contemplates the overcoming of these objections and the production of an enclosed sealed type relay capable of giving continued performance with the same operating characteristics over long periods of time without the necessity of replacing contacts or the like.

It is also contemplated within the scope of the present invention to provide a multiple contact construction within the envelope suitable for use as a motor starter or similar deyice in which a plurality of circuits may be closed simultaneously by the relay structure. Each of these circuits may lead to one phase of a three phase motor, or any other similar controlled device.

Other objects and'advantages of the present invention will appear more fully from the following detailed description which, taken in conjunction with the accompanying drawing, will disclose to those skilled in the art the particular construction and operation of a preferred form of the'present invention.

In the drawing:

Figure 1 is a sectional view of an envelope embodying our present invention;

Figure 2 is a bottom plan view of the structure shown in Figure 1, showing the manner in which the terminals are led into the envelope;

Figure 3 is an elevational view, partly in section, of a modified construction; and

Figure 4 is a diagrammatic view showing the manner in which a three-phase relay may be provided within the envelope.

Referring now in detail to the drawing, we have indicated in Figure 1 a metal envelope 5 having the enlarged open end 6 joined to the main body portion of the envelope by the frusto-conical shoulder I. Seated within the open end of the envelope against the shoulder edge is an insulating plug 8 which may be formed of ceramic, Bakelite, or any similar insulating material, and. which has a firm seat against the shoulder l, holding it against movement axially inwardly of the envelope. The plug 8 is provided with a reduced tapered extension 8 around which is adapted to extend a peripheral flange portion ill of a resilient sealing gasket l2, which gasket may be formed of rubber or similar sealing material. Pressed against the outer radial face of the gasket I2 is a compression disc [3, also formed of insulating material such as fiber or Bakelite, this member being substantially rigid. A suitable retaining ring it is pressed into the end of the envelope, and holds the gasket 12 compressed by being retained under the spun-over edge 15 of the envelope. This compression of the gasket [2 radially expands the same into sealing-engagement with the internal wall of the enlarged end 6 of the envelope, and also about the terminals projecting axially therethrough.

Preferably, the envelope has four such terminals extending therethrough when a single circuit controlling relay is provided. These terminals are indicated at ii, ll, l8 and IS in Figure 2. The terminals l6 and i8 form the two terminal connections to a solenoid coil Ill mounted within the bracket member 22 forming a support for the core 23 of the relay structure. The, bracket 22 is preferably secured to the inner radial face of the insulating plug I by the screws 2!, and the base portion of this bracket preferably has the enlarged openings 25 through which the terminal studs I i and II extend whereby they are insulated from the bracket 22; The two support for the coil and for the core 23,

The bracket is additionally provided with the normally extended arm portion 26 which, at its free end, is reduced to provide a pivot stud 21 for receiving the/end of the relay armature 28. The armature 28 is preferably provided with the enlarged opening 29 fitting about the stud 21 to accommodate pivotal movement thereabout. Preferably, a suitable spring 30 is biased between theextending car 32 of the armature 28, and a projecting portion 33 formed'at the base of the arm 26. This spring normally biases the armature 28 in acounter-clockwise direction relative to the pivot 21.

J Mounted on the armature 28 is the contact carrying member 29 provided with the spaced contact tip portion 30. The stud H which projects into the envelope parallel to'the stud I6 tion 34 adapted to be engaged by the contact 30.

p The second terminal stud i 9 has a pig tail connection 35 to the contact carrying arm 29, whereby upon energization of the coil 20, the core 23 attracts the armature 28 to the left, as viewed in Figure 1, closing the circuit between contacts 36 and 34, and consequently closing the circuit between the contact studs H and I9, This is the circuit controlled by the relay.

It will be noted that the terminals it to i9, inclusive, form rigid projections outwardly of the envelope, and the structure is adapted for seating in a socket or panel, if so desired, to establish circuit connections similar to the manner of connecting a radio tube through its prong extensions.

Upon deenergization of the coil 20, the spring 30 snapsthe' armature 28 in a counter-clockwise direction away from core 23, thereby providing a snap action breaking of contact between contacts 39 and 34, thereby opening the circuit between terminals ill and 59;

It will be noted that each of the terminals it to H9, inclusive, is provided with shouldered portions 36 set into corresponding recesses in the outer face of the insulating plug 8 whereby they are limited from axial inward movement, The

rubber gasket l2 seals the projecting portions of the terminals about the shouldered portions, thereby providing an effective seal preventing leakage of gas or moisture into or out of the open end of the envelope 5.

' At the closed end of the envlope there is provided a tubulation 4B which has a flange end 432 welded or otherwise suitably secured to the inner face of the closed end portion, and which can be connected to .a source of vacuum or a source of hydrogen or inert gas under pressure. When the parts have been assembled in the position shown in Figure 1, the tubulation is connected to the vacuum and the envelope is evacuated of all gases, moisture and the like, The tubulation is then connected to a'source of hydrogen gas under pressure or an inert gas, and the interior of the envelope filled with such gas under a pressure of from 2 to 3 atmospheres. With the pressure being maintained, the tubulation is pinched closed, as indicated at 43, and welded, thereby providing a sealed envelope within which the relay structure is disposed.

In the form of the invention shown in Figure 3, a metal envelope 45 is provided, which may be formed of non-magnetic material if so desired.

The open endof this envelope is counterbored to receive the disc 46, after which the projecting parallel arm portions of the bracket 22 form the g edge of the envelope is spun over, as indicated at 41, and welded to the outer face of the disc,

as indicated at 48, to provide a sealed connection therebetween. The disc 46 is adapted to carry the bracket 22 supporting the coil 20, and also has suitable openings therein through which extend the terminals 16 and 18 providing the connections to the coil. Preferably, the terminals i6 and i8 are sealed in position, as indicated at 49.

Also extending through the disc 46 are the terminals l1 and I9 corresponding to the terminals I! and 19 of Figure 2. Each of these terminals is provided with a reduced neck portion 50 at the point where it enters the disc 46, and a suitable glass sealing means 52 is provided for sealing the terminals ll and IS in position. This sealing means may comprise a borosilicate compound which has substantially the same coeiiicient of thermal expansion as the disc 46, thereby providing a tight seal therebetween. The operation of the structure shown in Figure 3 is similar to that shown in Figures 1 and 2..

In Figure 4 I have provided envelope 55 having.

the enlarged end portion 58 in which is disposed the insulating plug 51 formed of Bakelite or similar insulating material. I The armature 28 of the relay in this form of the invention is provided at its end with a laterally extending contact bridge member 58 provided with three terminal contact fingers 59, each carrying a contact 60 corresponding to contact 313 shown in Figure 1. In place of the single contact terminal I! of Figure 1, three contact terminals 62 are provided, each terminating at their inner end in a contact tip portion adapted to be engaged by the contact fill oi the fingers 69. The member 58 is preferably formed of resilient spring like material so that contact of all three fingers will be efiected upon energization of the coil 2t. Thus, three separate phases of a motor starter circuit can be closed simultaneously with the relay construction shown in Figure 4. The end of the envelope isclosed and sealed in the same manner as described in connection with Figure 1, and the envelope is evacuated and filled with a suitable gas under pressure through the opposite end thereof.

The contacts 30, 3t and 60 are preferably formed of-coin silver or the like to provide low resistance through the relay. The armature 28 in Figure 4 is provided with a pig tail connection to a terminal, such as the terminal member l9 whereby the circuit is led into the contact bridging member 58. in other respects, the operation of the device shown in Figure 4 is similar to that described in Figure l.

It is therefore believed apparent that we have provided a novel type of enclosed relay structure wherein the contacts will be protected against arcing, pitting and corrosion, with the entire re-- armature and fan actuating cofl, an enclosing shell of a non-magnetic metal resistant to the passage of gas 'therethrough, a ceramic insert in one end of said shell, said shell having an annular shoulder forming an abutment forsaid insert, means rigidly mounting said relay with its component parts on the inner face of said insert, elastic resilient sealing means overlying the outer 'face of said insert and having peripheral wedging action between said insert and the inner wall of said shell, compression means locked in the end of said shell engaging the outer face of said sealing means for maintaining it in compressed position against said insert and shell wall, and a filling of hydrogen gas under greater than atmospheric pressure in said shell.

2. An enclosed relay construction comprising a cup-shaped metal envelope having an annular shoulder intermediate its ends, an insulatin member inserted through the open end of said envelope into abutment against said shoulder, a normal open air contact type relay rigidly supported on the inner face of said member and including an actuating coil, a fixed contact and an armature, terminal posts for said coil, contact and armature extending axially through said member and having means limiting inward movement thereof relative to said member, a resilient variations. 

